Switch housing assembly held together by swaged terminals

ABSTRACT

A pair of switch housing members having sides thereof disposed in face-to-face relation and thereby defining a juncture line therebetween. A substantially flat terminal member projects out of the housing members substantially transversely to the juncture line while intersecting with the same so as to have opposed parts thereof disposed on opposite sides of the juncture line. The terminal member has the opposed parts thereof upset by a swaging action on the side edges thereof so that the opposed parts are upset out of the normal flat plane of the terminal member and are disposed against the respective housing members in directions respectively toward the juncture line and thereby tend to hold the housing members together in the face-to-face relation thereof without auxiliary fastening means.

United States Patent [1 1 Stearley et a1.

[ SWITCH HOUSING ASSEMBLY HELD TOGETHER BY SWAGED TERMINALS [75] Inventors: John W. Stearley, Grove City; Roger L. Warner, Union Township, both of Ohio [73] Assignee: Robertshaw Controls Company,

Richmond, Va.

[22] Filed: Oct. 16, 1972 [21] Appl. No.: 297,895

[52] US. Cl 174/59, 200/166 CT, 200/168 R,

339/220 R, 29/622 [51] Int. Cl. H011! 9/02 [58] Field of Search 200/168 E, 166 CT;

339/196 R, 196 M, 208, 220 R, 220 C; 174/59; 29/526, 622

[56] References Cited UNITED STATES PATENTS 3,221,094 11/1965 Cherry 174/59 3,091,838 6/1963 l-lild et a1. 339/220 R X 3,313,905 4/1967 Zagorski 200/166 BC OTHER PUBLlCATIONS Martin et al., Brazing Contacts," IBM Technical Dis- 1 Apr. 9, 1974 closure Bulletin; February, 1972, p. 2,594. Vol. 14, No. 9.

Primary Examiner-Robert K. Schaefer Assistant ExaminerWilliam J. Smith Attorney, Agent, or Firm-Candor, Candor & Tassone [5 7] ABSTRACT A pair of switch housing members having sides thereof disposed in face-to-face relation and thereby defining a juncture line therebetween. A substantially flat terminal member projects out of the housing members substantially transversely to the juncture line while intersecting with the same so as to haveopposed parts thereof disposed on opposite sides of the juncture line. The terminal member has the opposed parts thereof upset by a swaging action on the side edges thereof so that the opposed parts are upset out of the normal flat plane of the terminal member and are disposed against the respective housing members in directions respectively toward the juncture line and thereby tend to hold the housing members together in the face-to-face relation thereof without auxiliary fastening means.

10 Claims,.6 Drawing Figures SWITCH HOUSING ASSEMBLY HELD TOGETHER BY SWAGED TERMINALS This invention relates to an improved switch housing construction as well as to an improved method of making such a switch housing construction or the like.

It is well known that electrical switch constructions have been provided wherein each has a pair of cupshaped housing members of substantially rectangular configuration disposed with the open ends in abutting face-to-face relation to define an electrical switch casing having a chamber therein receiving the electrical switch parts that are adapted to be electrically connected to terminals projecting out of the assembled switch housing members and be actuated by a movable plunger also projecting out of the assembled housing members. Such assembled housing members can be secured together in their assembled relation by auxiliary fastening members, such as by nuts and bolts, rivets, and the like.

However, other means for securing such assembled housing members together other than auxiliary fastening members have been utilized such as specially designed tangs on the terminal members themselves which are subsequently bent into interlocking engagement with the assembled housing members, to hold the same together. For example, see the US. Pat. to Cherry, No. 3,221,094.

It is a feature of this invention to provide an electrical switch construction wherein a mere upsetting of one or more of the projecting terminal members, such as by a swaging action or the like, will cause an interlocking with the housing members in their assembled position to hold the same together.

For example, one embodiment of this invention provides a pair of switch housing members respectively having surface means disposed in face-to-face relation so as to define a juncture line therebetween. A substantially flat terminal member projects out of the assembled housing members substantially transversely to the juncture line and intersecting with the same so as to have opposed parts thereof disposed on opposite sides of the juncture line. The terminal member has the opposed parts thereof upset out of the normal flat plane of the terminal member and disposed against the respective housing members in directions respectively toward the juncture line to hold the housing members together in the face-to-face relation thereof.

Accordingly, it is an object of this invention to provide an improved switch construction having one or more of the novel features set forth above or hereinafter shown or'described.

Another object of this invention is to provide an improved method for making such a switch construction or the like.

Other objects, uses and advantages of this invention are apparent from a reading of this description, which proceeds with reference to the accompanying drawings forming a part thereof and wherein:

FIG. 1 is a top perspective view of the improved switch construction of this invention.

FIG. 2 is an enlarged end view of the switch construction illustrated in FIG. 1 and is taken in the direction of the arrows 2-2 of FIG. 1.

FIG. 3 is an enlarged end view of the switch construction of FIG. 1 and is taken in the direction of the arrows 3-3 of FIG. 1.

FIG. 4 is a fragmentary side view of the switch construction illustrated in FIG. 2.

FIG. 5 is an enlarged, fragmentary, cross-sectional view taken in the direction of the arrows 5-5 of FIG. 4 and illustrates the manner of interlocking the housing members together.

FIG. 6 is a view similar to FIG. I and illustrates in an exploded perspective view how the two housing members are assembled together.

While the various features of this invention are hereinafter described and illustrated as being particularly adapted for providing an electrical switch construction, it is to be understood that the various features of this invention can be utilized singly or in any combination thereof to provide means for securing other types of housing members together as desired.

Therefore, this invention is not to be limited to the embodiment illustrated in the drawings, because the drawings are to be utilized to illustrate one of the wide variety of the uses of this invention.

Referring now to FIG. 1, the improved electrical switch construction of this invention is generally indicated by the reference numeral 10 and comprises a housing means or switch casing that is generally indicated by the reference numeral 11 and is formed from two housing members 12 and 14 disposed in face-toface relation to define a juncture line 15 therebetween, the electrical switch construction 10 including a pair of terminal members 16 and 17 extending out of one end 18 of the casing 11 and another terminal member 19 extending out of the other end 20 of the casing 11. A switch actuating plunger 21 extends out of an opening 22 formed in the top 23 of the casing 11 for operating suitable switch mechanism (not shown) that is disposed inside the switch casing 11 and is adapted to switch the electrical connection between the terminals 19 and 16 to the terminals 19 and 17 depending upon the position of the plunger 21 relative to the casing 11 in a manner conventional in the art. Thus, the details of the electrical switch mechanism need not be illustrated or de-' scribed as it is to be understood that any conventional switching mechanism can be utilized in the casing 11 for causing the electrical switching function between the terminal 19 and the terminal 16 or 17 upon actuation of the plunger 21.

As illustrated in FIG. 6, the housing members 12 and 14 are substantially cup-shaped with a generally rectangular configuration so that when the surface means 24 and 25 at the respective open ends 26 and 27 of the housing members 12 and 14 are disposed in the assembled face-to-face relation illustrated in FIG. 1, a compartment means 28 is formed between the housing members 12 and 14 to contain the electrical switching mechanism previously described.

Each terminal member 16, 17 and 19 can be provided with stepped opposed side edges 29 and 30 to define an inner larger section 31, and intermediate reduced section 32 and an outer reduced section 33 as illustrated in FIG. 6. The housing members 12 and 14 can be respectively provided with slot means 34, 35 and 36 which cooperate with each other so as to be aligned together when the housing members 12 and 14 are assembled together in the manner illustrated in FIGS. 1, 2 and 3. The cooperating slot means 34, 35 and 36 are so constructed and arranged that the terminals 16, 17 and 19 can respectively project out through the aligned slot means 34, 35 and 36 as illustrated in the drawings with the intermediate parts 32 of the terminals 16, 17 and 19 fully fitting within the aligned slot means 34, 35 and 36 while the larger parts 31 of the terminals 16, 17 and 19 are confined within the chamber 28 of the switch casing 11 and cannot pass out through such aligned slot means 34, 35 and 36.

The housing members 12 and 14 are respectively provided with recesses 37, 38 and 39 which respectively lead to the slot means 34, 35 and 36 of the respective housing member 12 and 14 to define shoulder means 40, 41 and 42 respectively on the housing members 12 and 14, the shoulder means 40, 41 and 42 being adapted to be disposed spaced from and parallel to the juncture line 15 at the respective ends 18 and 20 of the switch casing 11 as illustrated in FIGS. 2 and 3. Each shoulder means 40, 41 and 42 is divided into a pair of shoulders respectively disposed on opposite sides of the cooperating slot means 34, 35 and 36 of the casing 11 as fully illustrated in FIGS. 2, 3 and 5.

After the housing members 12 and 14, switch structure and terminals 16, 17 and 19 have been assembled together into the complete configuration illustrated in FIG. 1, a suitable swaging tool (not shown) is inserted in the recesses 37, 38 and 39 of the housing members 12 and 14 respectively against the side edges 29 and 30 of the terminals 16, 17 and 19 and through one or more sharp blows thereon cause an upsetting of the side edges 29, 30 of the terminal members 16, 17 and 19 toward the juncture line 15 whereby like upset parts 43 of the terminal members l6, l7 and 19 are respectively forced against the shoulder means 40, 41 and 42 of the housing members 12 and 14 on both sides of the respective terminal members 16, 17 and 19 and thus, out of the normal flat planes of the terminal members 16, 17 and 19 as illustrated to interlock against the shoulder means 40, 41 and 42 whereby the housing members 12 and 14 are secured together in the assembled faceto-face relation illustrated in the drawings solely by the upset parts 43 of the terminal members 16, 17 and 19. Such upset parts 43 of the terminal members 16, 17 and 19 also prevent the movement of the terminals members 16, 17 and 19 into the switch casing 11 whereby the terminal members 16, 17 and 19 are now locked from axial movement relative to the switch casing 11.

Thus, it can be seen that not only is an improved electrical switch construction provided by this invention, but also an improved method of assembling or making such an electrical construction is provided by this invention wherein merely the side edges 29 and 30 of the terminal members 16, 17 and 19 are upset by a simple swaging action out of the normal flat planes of the respective terminal members 16, 17 and 19 to be disposed against the respective housing members 12 and 14 to secure the same together in their face-to-face relation as illustrated in FIG. 1.

Of course, while only one terminalmember 19 is illustrated as extending out of the end 20 of the casing 11 and two terminal members 16 and 17 are illustrated asextending out of the end 18 thereof, it is to be under stood that any number of terminal members can extend out of the casing 11 at any desired location thereon and be utilized to secure the housing members 12 and 14 together through the upsetting of the metal thereof toward the juncture line 15 in the manner previously described.

Therefore, it can be seen that this invention not only provides an improved electrical switch construction or the like, but also this invention provides an improved method of making an electrical switch construction or the like.

While the form and method of the invention now preferred have been disclosed and described as required by the Patent Statutes, other forms and methods may be utilized and still come within the scope of the appended claims.

What is claimed is:

1. In combination, a pair of switch housing members respectively having surface means disposed in face-toface relation defining a juncture line therebetween, and a substantially flat terminal member projecting out of said housing members substantially transversely to said juncture line and intersecting the same to have opposed parts thereof disposed on opposite sides of said juncture line, said terminal member having said opposed parts thereof upset out of the normal flat plane of said terminal member and' disposed against the respective housing members in directions respectively facing toward said juncture line to tend to hold said housing members together in said face-to-face relation whereby the upset parts are thicker in cross section than the parts of said terminal member adjacent thereto.

2. A combination as set forth in claim 1 wherein each upset part of said terminal member is upset out of said plane on both sides thereof. 7

3. A combination as set forth in claim 1 wherein said housing members define a switch casing having opposed ends, said terminal member projecting out of one of said ends of said switch casing.

4. A combination as set forth in claim 3 wherein another terminal member projects out of the other end of said switch casing and likewise has opposed parts thereof upset out of the normal flat plane thereof and disposed against the respective housing members in directions respectively facing toward said juncture line to tend to hold said housing members together in said face-to-face relation whereby the upset parts of said other terminal member are thicker in cross section than the parts of said other terminal member adjacent thereto.

5. A combination as set forth in claim 4 wherein a third terminal member projects out of one of said ends of said casing in spaced relation to the respective terminal member at that end, said third terminal member likewise having opposed parts thereof upset out of the normal flat plane thereof and disposed against the respective housing members in directions respectively facing toward said juncture line to tend to hold said housing members together in said face-to-face relation whereby the upset parts of said third terminal member are thicker in cross section than the parts of said third terminal member adjacent thereto.

6. A combination as set forth in claim 1 wherein each said housing member has. shoulder means disposed spaced from and substantially parallel to said juncture line, said parts-of said terminal member that are upset being upset respectively against said shoulder means.

7. A combination as set forth in claim 6 wherein each of said housing members has a recess formed therein and leading to said shoulder means thereof.

8. A combination as set forth in claim 7 wherein each housing means has a slot therein that leads from said surface means thereof through said shoulder means thereof to define two shoulders on opposite sides of said slot, said terminal member projecting out of said slots of said housing members.

9. A combination as set forth in claim 8 wherein each shoulders of the respective housing member.

10. A combination as set forth in claim 9 wherein each upset part of said terminal is formed by swedging a side edge of said terminal member toward said shoulupset part of said terminal member is upset out of said 5 der means of the respective housing member.

plane on both sides thereof to be disposed against both 

1. In combination, a pair of switch housing members respectively having surface means disposed in face-to-face relation defining a juncture line therebetween, and a substantially flat terminal member projecting out of said housing members substantially transversely to said juncture line and intersecting the same to have opposed parts thereof disposed on opposite sides of said juncture line, said terminal member having said opposed parts thereof upset out of the normal flat plane of said terminal member and disposed against the respective housing members in directions respectively facing toward said juncture line to tend to hold said housing members together in said face-to-face relation whereby the upset parts are thicker in cross section than the parts of said terminal member adjacent thereto.
 2. A combination as set forth in claim 1 wherein each upset part of said terminal member is upset out of said plane on both sides thereof.
 3. A combination as set forth in claim 1 wherein said housing members define a switch casing having opposed ends, said terminal member projecting out of one of said ends of said switch casing.
 4. A combination as set forth in claim 3 wherein another terminal member projects out of the other end of said switch casing and likewise has opposed parts thereof upset out of the normal flat plane thereof and disposed against the respective housing members in directions respectively facing toward said juncture line to tend to hold said housing members together in said face-to-face relation whereby the upset parts of said other terminal member are thicker in cross section than the parts of said other terminal member adjacent thereto.
 5. A combination as set forth in claim 4 wherein a third terminal member projects out of one of said ends of said casing in spaced relation to the respective terminal member at that end, said third terminal member likewise having opposed parts thereof upset out of the normal flat plane thereof and disposed against the respective housing members in directions respectively facing toward said juncture line to tend to hold said housing members together in said face-to-face relation whereby the upset parts of said third terminal member are thicker in cross section than the parts of said third terminal member adjacent thereto.
 6. A combination as set forth in claim 1 wherein each said housing member has shoulder means disposed spaced from and substantially parallel to said juncture line, said parts of said terminal member that are upset being upset respectively against said shoulder means.
 7. A combination as set forth in claim 6 wherein each of said housing members has a recess formed therein and leading to said shoulder means thereof.
 8. A combination as set forth in claim 7 wherein each housing means has a slot therein that leads from said surface means thereof through said shoulder means thereof to define two shoulders on opposite sides of said slot, said terminal member projecting out of said slots of said housing members.
 9. A combination as set forth in claim 8 wherein each upset part of said terminal member is upset out of said plane on both sides thereof to be disposed against both shoulders of the respective housing member.
 10. A combination as set forth in claim 9 wherein each upset part of said terminal is formed by swedging a side edge of said terminal member toward said shoulder means of the respective housing member. 